Production of biochar absorbent from anaerobic digestate

ABSTRACT

A novel carbon absorption material is described which is formed from anaerobic digestate. The material has a hollow tubular structure and is particularly advantageous in converting hydrogen sulfide in biogas and in absorbing the converted sulfur and sulfur compounds from biogas into its structure. The material after use as a hydrogen sulfide absorbent has value as a horticultural or agricultural product or as a sulfur impregnated activated carbon. The process for producing this novel carbon absorption material is described. In an embodiment, the process described uses in particular, a humidified inert gas over a temperature range of between about 500° C. to 900° C. to convert anaerobic digestate to an active carbon absorbent. The thermal treatment is relatively mild and retains the fibrous structure of the source material while removing cellulosic and hemicellulosic components from the anaerobic digestate.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit and priority to U.S. patentapplication Ser. No. 13/937,675 filed on Jul. 9, 2013, which claims thebenefit and priority to PCT International Application No.PCT/CA2012/000022 filed on Jan. 12, 2012, which was published inaccordance with PCT Article 21(2) on Jul. 19, 2012 in English and whichclaims the benefit of U.S. Provisional Patent Application No. 61/432,947filed on Jan. 14, 2011, all of which are incorporated by referenceherein.

FIELD OF THE INVENTION

This invention relates to the formation of a novel type of carbonizedabsorbent which is particularly suitable for removing sulfurcontaminants from biogas. The carbonized absorbent after use has valuein horticulture and agriculture.

BACKGROUND TO THE INVENTION

The development of non-petroleum sources of fuels is important in longterm energy sustainability for most countries. One of these potentialsources is from growing biomass and directly or indirectly using thefuel value. A criticism of this approach is that productive farm landmay be displaced for these fuel crops. A less controversial source ofenergy is from wastes produced from agriculture. These materials includeanimal wastes, food wastes and crop residues. These materials may beused to produce methane using anaerobic digestion technology. Methane isthe primary component of Natural Gas and may be substituted for NaturalGas in many applications. Methane when pure is a very clean burning fueland can be used in vehicles, for heating and when used as the fuel foran engine in an electrical generator can produce electricity. Althoughthere are many potential sources of wastes that could be anaerobicallydigested, most are not utilized at the present time because ofunfavorable economic payback for small-scale systems. One of thesignificant issues is that the methane produced from anaerobic digestionis not pure but contains substantial amounts of carbon dioxide, an inertgas that dilutes the fuel value of the biogas, and contains contaminantssuch as sulfur compounds which have an unpleasant odor and causesignificant corrosion and environmental emissions. Removal of thesesulfur compounds is thus an important step in utilizing biogas.

Many techniques are known for sulfur compound removal from gases.Reactions of the compounds with iron or zinc oxides with or withoutcatalysts, are commonly used in large scale systems where disposal ofthe reacted products is not a significant issue or cost. Membranetechnology is also used in large systems where there is sufficientexpertise on staff to maintain the operation. For smaller scale systemswater scrubbing and carbon absorption beds have been used. These systemsare relatively easy to operate but also produce wastes which requiredisposal. These wastes typically have significant odor from hydrogensulfide, a common sulfur compound produced during anaerobic digestion.Hydrogen sulfide is a toxic gas as well as being odorous whichcomplicates the waste disposal.

The production of charcoal from biomaterials is known. The focus was onproducing a relatively clean burning solid, a fuel still used inbarbecues and cooking stoves. The non-carbon elements are removed byheating the biomaterial in the absence of air and causing thevolatilization of these species. More recently, there has been emphasison converting as much of the biomaterial as possible to volatiles thathave fuel value in a process known as pyrolysis. The residual carbon inboth cases is somewhat porous but does not have high surface area. Forhigh surface area carbon absorbents, chemical treatment is appliedeither before pyrolysis or afterwards with a second thermal treatment.This is often followed by a water wash to remove the activating chemicalor the unwanted ash.

For activated carbon production, two steps are used. The first producesthe elemental carbon and the second activates the carbon. For producingactivated carbons with specific absorption characteristics a third stepis used in which specific catalytic chemicals are loaded onto the carbonsurface. As should be clear, the cost of the activated carbon productincreases with the extent of processing required for the final product.

The use of waste materials as a source for activated carbon productionis not commonly discussed because the carbon content is relatively low.In an article by Chen et al. (“Physical and Chemical Properties Study ofthe Activated Carbon made from Sewage Sludge 2002, Waste Management, 22,755-760) they describe the use of sewage sludge; an anaerobicallydigested residue from municipal waste water treatment. Zinc chloride wasrequired as an activating agent to enhance the surface area of thecarbon product and the carbon content of the activated carbon was only38.9% C by weight.

The use of anaerobic sludge was also reported to be poor for activatedcarbon production by Tay et al. In a publication entitled “A ComparativeStudy of Anaerobically Digested and Undigested Sewage Sludges inPreparation of Activated Carbons” Chemosphere 2001, 44, 53-57, Tay etal. found that the undigested sludge produced an activated carbon withhigher carbon content, lower ash content, higher surface area and betterphenol adsorption characteristics. Thus the use of digested sludge isdiscouraged.

Martin et al. (“Feasibility of Activated Carbon Production fromBiological Sludge by Chemical Activation with ZnCl2 and H2SO4”,Environmental Science and Technology 1996, 17, 667-672) showed thatoptimal activation conditions produced a surface area of 257 m²/g withan ash content of 38% and a yield of 34%. This material had acontaminant removal of only 20% of that for a commercial activatedcarbon. Again this suggests that anaerobic sludge is a poor material foractivated carbon production.

In a patent on activated carbons from animal manures (U.S. Pat. No.7,524,795 issued to Lima et al.) a process is described wherebycarbonization of poultry manure followed by activation is used toproduce an activated carbon with good metal ion adsorptioncharacteristics. In this work, the starting material is raw poultrymanure and not the anaerobic sludge digestate from poultry manure.

A patent by Freel et al. (U.S. Pat. No. 7,199,080) describes howagricultural corn derivatives can be used to produce activated corncarbon. The process involves pyrolysing the corn derivatives to generatecarbon char and then activating the char using a steam activation stage.An additional acid washing step is also suggested to remove ash from theproduct. This process differs from the current process by being a 2 stepoperation and by starting with raw corn derivatives and not theanaerobically digested solids.

Bandosz et al. (U.S. Pat. No. 6,962,616) teach a process for removingacidic sulfur species from wet gas streams using a carbon absorptionmaterial which is produced from dewatered and dried sewage sludge. Thisprocess for sewage sludge preparation requires a drying operation,addition of mineral oil and a pyrolyzing step before the carbon materialis ready for use as a adsorbent. It will be clear that the currentprocess has advantages over the process of Bandosz et al. in that nomineral oil is required and the starting material is from anaerobicdigestate solids and not restricted to sewage sludges. When used forremoving acidic sulfur species from a gas stream Bandosz et al. rely oninorganic constituents from the pyrolyzed solids to convert hydrogensulfide. In claim 3 the authors state that the hydrogen sulfide reactswith the inorganic constituents of the carbon to produce sulfur dioxideor elemental sulfur or salt forms thereof. In the current process forremoving hydrogen sulfide from the gas stream there is insufficientinorganic content or chemicals to oxidize the hydrogen sulfide in thegas stream. For the current process a small percentage of oxygen or airshould be added to the gas stream and is the oxidant which convertshydrogen sulfide to either sulfur or solid oxidized sulfur compounds.The use of a low percentage of air addition to the gas stream to becleaned is particularly advantageous in maximizing the capacity of ourcarbon material for hydrogen sulfide removal. Without this addition,hydrogen sulfide is simply adsorbed and would be a problem for the usedabsorbent carbon disposal. This is also a problem for commercialactivated carbons which can adsorb hydrogen sulfide but are not able toconvert hydrogen sulfide to elemental sulfur or oxidized sulfur salts.

The carbon material produced by the current process has the capabilityof converting essentially all of the hydrogen sulfide in the gas streamto sulfur or oxidized sulfur solids when the gas stream has a fewpercent air addition. The conversion of hydrogen sulfide to elementalsulfur has a significant advantage in that the used absorbent carbonsolids can then be utilized as a secondary value-added product inhorticulture or agriculture.

A patent by Beckler and Miller (U.S. Pat. No. 6,277,780) describespreparation of an activated carbon from a variety of carbonaceoussources and a thermal treatment, but in order to make this materialsuitable as an absorbent the material must be loaded with a phosphorouscontaining chemical. Clearly simple heat treatment is not sufficient forpreparation of a carbon absorbent.

A patent by Khalili et al. (U.S. Pat. No. 6,030,922) describes thepreparation of an activated carbon from raw sludge but which requireschemically activating the dried sludge material before thermaltreatment. It is clear that this chemical addition is required toproduce a useful activated carbon.

A patent by Piskorz et al. (U.S. Pat. No. 5,853,548) describes a twostage process for converting biosolids into fuels and for further heattreating the residual char to produce an activated carbon. In the firststage a temperature range of 390 to 450° C. was used. In the currentprocess, the minimum temperature that was found to be effective was 500°C. A significant difference is that the Piskorz et al. patent hasfocused on using shredded biomass material rather than anaerobicdigestate that is used in the current process. Microbial degradation ofbiomass in anaerobic digesters reduces the content of readily degradableorganic species and hence would reduce the fuel value of the material.The second stage char treatment in the Piskorz et al. patent attempts tominimize the char volume by heating at a temperature of 700° C. forthermal annealing. In the current process, production of an absorbentcarbon is the intended product and its minimization is not a desirablegoal.

In a patent by Abe et al. (U.S. Pat. No. 5,338,462), a method fordecomposing water contaminants such as hydrogen peroxide, hydrazines,quaternary ammonium salts, organic acids and sulfur-containing compoundsusing an activated carbon is described. The hydrocarbon source materialis a nitrogen-rich protein-containing sludge or a waste materialcomprising microbial proteins or biologically activated sludge. Thismaterial is first carbonized at a temperature of from 150° C. to 600° C.then activated at a temperature of from 700° C. to 1,100° C. in an inertgas or a reducing gas atmosphere consisting essentially of steam orgaseous carbon dioxide.

It should be clear that the carbon sources and the end use applicationsare very different in the Abe et al. patent compared to the currentapplication. The current process claims as a starting materialacidogenic digestate which is the fibrous undigested cellulosic andlignin structures from anaerobic digestion of waste materials and notthe biologically activated sludge material in the patent by Abe et al.The nitrogen content of our starting material would be poor for thepurposes claimed in the patent by Abe et al. and the microbial proteinsrequired by the patent by Abe et al. by would not have the structurerequired for producing our carbon absorbent.

In a patent by Lewis (U.S. Pat. No. 4,122,036), a process for pyrolysingsewage sludge to produce activated carbon is described. The sewagesludge, which has a high moisture content is mixed with recycled hotchar from a rotating kiln to produce a dry, free-flowing product whichis fed into the kiln. It is clear that this patent does not teach theconditions required by the current technology for producing a carbonabsorbent from anaerobic digestate.

Thus, what is needed is an improved process for producing a carbonabsorbent material from anaerobic digestate.

SUMMARY OF THE INVENTION

The current invention addresses a number of the problems as identifiedfurther above. More particularly, the invention uses a carbon source(acidogenic digestate) which is available from the anaerobic digestionprocess, thus avoiding environmental impact of purchasing and usingactivated carbons produced from coals and petroleum sources.

More particularly, the inventors have developed a novel carbon absorbentmaterial from anaerobic digestate which possesses enhanced activity forcleaning biogas and which creates a valued-added sulfur-containingbyproduct after use.

The potential for on-site generation has additional benefits ineliminating transportation green-house gas emissions. The carbonabsorbent does not use or require chemical additives such as potassiumhydroxide for pore development or activation. The carbon absorbent isproduced in a single operation thus simplifying production.

The carbon produced does not simply adsorb hydrogen sulfide from biogasbut converts it to a useful form of sulfur and thus creates a usefulbyproduct rather than a noxious waste material. This property does notrequire treatment of the carbon with catalysts or chemical additives. Asa result of the avoidance of chemical additions, the used carbon can beapplied advantageously to horticulture and agricultural operation, thuseliminating any waste generation or disposal problems.

The carbon adsorbent is created without the requirement for chemicaladditions for pore enhancement or surface activity and is an ecofriendlymaterial for use in horticulture, agriculture or as a generic adsorbentfor water or airborne contaminants.

A further object of this invention is to provide a method to producesaid carbon absorbent material from anaerobic digestate.

BRIEF DESCRIPTION OF THE DRAWINGS

In order that the invention may be better understood, a preferredembodiment is described, by way of example only, wherein:

FIG. 1 is a schematic of the apparatus used for heat treating theanaerobic digestate solids;

FIG. 2 is a schematic of the apparatus used for the gas absorptionmeasurements;

FIGS. 3A and 3B illustrate Scanning Electron Microscopy (SEM) analysisof heat treated anaerobic digestate;

FIG. 4 is an example of the characterization of the anaerobic digestatematerial using TGA; and

FIG. 5 is an example of the analysis of the sulfur species after theheat treated carbon absorption material has been used for hydrogensulfide removal.

DETAILED DESCRIPTION OF THE INVENTION I. Preparation of the CarbonAbsorbent Material

Samples of anaerobic digestate were obtained from a dairy farmprocessing animal manure in an anaerobic digester. The solids from thedigester were filter pressed then put in piles where the samples weretaken. Samples consisting of 30 grams (air dry weight) of material wereplaced in a quartz tube fitted with a fritted disk to support thesamples. The tube was inserted into a tube furnace and inert gas(nitrogen) was directed through the tube. The tube was heated to atemperature set between 400 and 900° C. for 1 hour and then allowed tocool. For some samples, the nitrogen gas was humidified and thetemperature of the furnace was set at a temperature between 500 to 850°C. The sample weight after thermal treatment was recorded. A schematicof the apparatus is shown in FIG. 1.

II. Specific Surface Area and Porous Structure Analysis

The measurement of surface area and porous structure was conducted byusing a Quantachrome Autosorb Automated Gas Sorption System, surfaceanalyzer (Model SA 3100, Coulter Corp., Miami, Fla.). Nitrogen wasselected as the adsorbate for the measurement and helium was chosen asthe balancing gas. The adsorption isotherm can be obtained by plottingvolume of nitrogen adsorbed against the relative pressure of nitrogen.BET surface area is determined using a BET model.

III. Absorption Capacity

The capacity of the carbon absorbent was determined using an absorptionanalysis technique. A schematic of the apparatus is shown in FIG. 2. Aweighed sample of the carbon absorbent was placed in a 1.1 cm glass tubewith fritted disks above and below the sample. A gas containing variousmixtures of carbon dioxide, nitrogen, air, methane, water vapor andhydrogen sulfide were passed through the carbon absorbent material. Flowrates of the gases were controlled using Aalborg mass flow controllers.The concentration of hydrogen sulfide was measured using an IndustrialScientific GasBadge Pro electrochemical gas detector. The time requiredbetween the start of hydrogen sulfide flow, which was set to provide aconcentration of 450 ppm in the inlet gas mixture into the carbonabsorbent, until at least 100 ppm could be measured in the outlet gascomposition was recorded. This time is referred to as breakthrough time.The amount of hydrogen sulfide removed from the gas stream during thisperiod per mass of carbon absorbent used in the column was computed andreported as absorption capacity in units of mg of hydrogen sulfide pergram of carbon absorbent. The weight gain of the sample was alsomeasured to confirm the uptake of the hydrogen sulfide.

IV. Analysis of Absorbed Sulfur Species

The determination of the form of sulfur species on the carbon absorbentwas conducted using a technique called Xray Photoelectron Spectroscopy(XPS). In this technique, the energy of electrons ejected from thesample irradiated by a monochromatic Al K_(α) x-ray source was analyzed.The energy of electrons ejected from an irradiated sulfur atom dependson its oxidation state and through correlation with known standards canbe determined to be either −2, 0, +4, or +6. An example for the sulfuranalysis is shown in FIG. 5

V. Elemental Analysis

The analysis of the elemental composition of the carbon material wasconducted using a technique called Inductively Coupled Plasma AtomicEmission Spectroscopy (ICPAES) using a Perkin Elmer model Optima 7300DVICP AEOS.

VI. Sample Morphology

Sample morphology was determined using a technique known as ScanningElectron Microscopy (SEM) as well as optical microscopy. An example ofthe analysis is shown in FIGS. 3A and 3B.

VII. Digestate Sample Characterization

The raw digestate samples were characterized using ThermogravimetricAnalysis (TGA). In this analysis, a sample is heated in a controlledincreasing temperature manner under a nitrogen gas flow while the samplemass is continuously recorded. Loss of mass due to water, cellulose,hemicellulose and lignin were identified at different temperatures. Anexample of the analysis is shown in FIG. 4.

An illustrative embodiment of the invention will now be described withreference to the figures.

FIG. 1 shows a schematic of the thermal treatment apparatus including aninert gas source (11) such as nitrogen or carbon dioxide or argon orbiogas or exhaust combustion gas. Also shown is a mass flow controller(12), such as an Aalborg Gas Mass Flow Controller for inert gas flowrate control. Valves (13) direct gas flow, and in FIG. 1 the valve shownallows the inert gas to be either dry or humidified by directing the gasto a humidifier (14).

Still referring to FIG. 1, in an embodiment, humidifier (14) is a gasbubbler used to force the inert, dry gas to contact water in the vessel.The temperature of the water in the humidifier can be increased toincrease the relative humidity of the gas. In an embodiment, therelative humidity may range from about 2% to 95%. More preferably, therelative humidity should be greater than about 10%.

A furnace (15) is shown to provide a heat source, and in an embodimentmay be a temperature controllable Carbolite tubular furnace. Although atube furnace is used in this illustrative example, in principle, anyheating apparatus such as fluidized bed, rotating kiln, hearth roastercould be used, provided that the inert gas used has low or no oxygenpresent. A pyrolysis furnace in which there is no inlet gas flow couldalso be used, but achieving the beneficial effect of a humidified gasflow would be difficult to achieve.

Still referring to FIG. 1, also shown is an anaerobic digestate sample(16). In this illustrative example, a sample of digestate solids isplaced on a fritted disk fitted in a quartz tube. A second fritted diskis placed on top of the sample to ensure there are minimal losses of thesample during heat treatment. A porous quartz fritted disk (17) is usedto support the sample, and a second fritted disk is placed on top of theanaerobic digestate sample in order to avoid losses of the digestatesolids.

Exhaust gas (18) shown in FIG. 1 contains all the volatile hydrocarbonsfrom the digestate sample, and additionally any carbon-containingcompounds produced during the heat treatment. Thus, this exhaust gas(18) may be optimally used as a supplemental fuel for heating thefurnace.

Now referring to FIG. 2, shown is a schematic of the apparatus used fordetermining hydrogen sulfide capacity. For the purpose of demonstration,the gas to be treated (21) was prepared synthetically using pressurizedgas from a cylinder. The synthetic gas was doped with hydrogen sulfidecontaminant (0-3000 ppm) (22). An additional component was added (air oroxygen at a concentration of 0.01-5 vol % of synthetic gas to betreated). The flow rates were set using mass flow controllers (24) foreach gas stream and gases were combined and flowed to the absorptioncolumn (25) which held the carbon absorbent (26). A weighed mass ofcarbon absorbent was held between two fritted disks in the absorptioncolumn. The hydrogen sulfide concentration was measured using anIndustrial Scientific GasBadge Pro hydrogen sulfide concentrationmonitor. The treated gas from the absorption column was vented to theatmosphere (29)

EXAMPLES I. Example 1

The effect of temperature on the anaerobic digestate was tested. Usingthe experimental set-up shown in FIG. 1, samples of anaerobic digestatesolids were taken. A 30 gram (dry weight) sample of material was placedin a quartz tube fitted with a fitted disk to support the sample. Thetube was inserted into a tube furnace and inert gas (nitrogen) wasdirected through the tube. The tube was heated to a temperature set ateither 400° C., 500° C. or 700° C. for 1 hour and then allowed to cool.The samples were then tested in the apparatus shown in FIG. 2 todetermine their hydrogen sulfide absorption capacity as described. Theresults showed that the capacities were 0.3 for the 400° C., 2.2 for the500° C. and 4.1 for the 700° C. in units of mg H₂S per gram of heattreated absorbent carbon. All of these absorbent capacities are low. Itis especially clear that treatment at 400° C. for 1 hour does not yielda useful absorbing material.

II. Example II

The beneficial role of oxygen or air addition to a gas to be treated forhydrogen sulfide removal using the absorbent carbon will bedemonstrated. Samples of the absorbent carbon produced at 700° C. inExample 1 were tested in the apparatus shown in FIG. 2 to determinehydrogen sulfide absorption capacity. For this test, air was meteredusing the mass flow meter (24) from a compressed gas cylinder (23) intothe gas stream containing hydrogen sulfide to provide a 2% air additionto the gas sent to the absorption column. In this test the break-throughtime was considerably increased and the capacity at break through wasdetermined to be 35.8 mg H₂S per gram of heat treated absorbent carbon.The dramatic increase in absorption capacity with small additions of anoxidant such as air demonstrates that the absorbent carbon can utilizean external oxidant and does not have to rely on reactive oxygen groupson the carbon surface to interact with hydrogen sulfide.

III. Example 3

The effect of moisture during the heat treatment on the absorptioncapacity of the absorbent carbon was tested. A sample which had beenheat treated as in Example 1 was additionally heated in the presence ofhumidified nitrogen at a temperature of 850° C. for one hour. Thenitrogen gas was humidified by bubbling the gas through water at roomtemperature before passing into the tube containing the sample. Thecapacity determined using the procedure used in Example 2 (2% airaddition) increased significantly to 177.0 mg H₂S per gram of heattreated absorbent carbon. This capacity increase was so dramatic thatthe experiment was repeated on three additional samples. The averagecapacitance value for the four samples was 286.8 mg H₂S per gram of heattreated absorbent carbon. It is clear that the use of a humidified gasflow through the sample during a two stage heat treatment is veryimportant in achieving high absorption capacity.

IV. Example 4

In order to determine whether the humidified heat treatment could beadvantageously applied to sample heat treated at other temperatures,four separate samples were heat treated at 500° C. for one hour thenwere additionally heated in the presence of humidified nitrogen at atemperature of 850° C. for one hour. For these samples the averagecapacity was 407.4 mg H₂S per gram of heat treated absorbent carbon.Again the second stage of humidified gas treatment increased thecapacitance in a very significant manner.

In order to determine whether the humidification could be conducted in asingle temperature treatment step, a sample was heat treated for onehour at 850° C. with humidified nitrogen gas. In this example, the heattreated sample had a capacitance of 330 mg H₂S per gram of heat treatedabsorbent carbon. Thus, the beneficial effect of humidifying the inertgas passing through the sample at the heat treatment temperature isdemonstrated. Single heat treatment processes have a numerous benefitsover two stage treatments in terms of capital and operating costs andprocessing time.

V. Example 5

The cause of the very high absorption capacity of the thermally treatedsamples was investigated using SEM as described earlier. FIG. 3 shows ahighly magnified view of the absorbent carbon. The morphology clearlyshows carbonized hollow fiber tubes. Thus the fibrous nature of the rawdigestate has been retained after the thermal treatment. The structureappears to be unique and may be the cause of the high absorptioncapacity.

VI. Example 6

The nature of the anaerobic digestate which leads to the formation ofthe absorbent carbon through the thermal heat treatment was investigatedusing Thermal Gravimetric Analysis as described earlier. FIG. 4 shows athermogram of the response of a sample being heated at 10° C. per minuteto a temperature of 950° C. The weight loss curve (a) begins at anormalized initial sample weight of 100%. As the temperature rises,volatile species are lost and the weight decreases. Different specieshave different volatilization temperatures. For example, the weight lossbeginning at 100° C. is due to evaporation of residual water. Thetemperature regions for loss of different species is more easilyidentified by plotting the rate of weight loss (curve b) as a functionof temperature. For this curve, there is a peak at 150° C. representingthe loss of water starting at 100° C. and being complete by about 180°C. There are two other overlapping peaks at about 325° C. and 390° C.which represent the loss of hydroxyl groups from hemicellulose andcellulose. At higher temperatures there is a slow, continuing loss ofweight likely due to lignin degradation. The results clearly indicatethat at the thermal temperatures used for anaerobic digestate treatment,water, and then the hydroxyl groups from hemicellulose and celluloseshould be fully removed from the sample. The relatively gentle thermalconditions are likely responsible for retaining the fiber structure inthe treated samples seen in FIG. 3.

VII. Example 7

The nature of the hydrogen sulfide absorption on the carbon absorbentwas analyzed using XPS as described earlier. FIG. 5 shows the XPSspectrum of the sulfur found on a humidified, heat treated, absorbentcarbon after hydrogen sulfide absorption. There are two prominent peakscorresponding to sulfur oxidation states of 0 and +6. There is noevidence of a peak between 161 and 162 eV which would represent hydrogensulfide. Thus the analysis shows that the carbon absorbent producedconverts hydrogen sulfide to higher oxidation states and avoids any odorissues by eliminating hydrogen sulfide entirely.

Thus, in an aspect, there is provided a carbon absorbent materialproduced from anaerobic digestate (acidogenic digestate) through heattreatment at greater than or equal to 500° C., which remainsstructurally intact despite losing the hydroxyl groups of the celluloseand hemicellulose and which retains its non-hydrocarbon elements.

In an embodiment, a carbon absorbent material produced from anaerobicdigestate of animal manures through heat treatment with a humidified gasat greater than or equal to 500° C. which remains structurally intactdespite losing the hydroxyl groups of its cellulose and hemicellulosecontent and retains its non-hydrocarbon elements.

In another aspect, there is provided a process for producing a carbonabsorbent material which comprises all or some steps of:

-   -   a. Feeding dewatered anaerobic digestate into a vessel (thermal        reactor) which is heated to a temperature of 500° C.;    -   b. Passing humidified non-combustible gas through the sample in        the reactor for greater for a period of 30 minutes or longer    -   c. Withdrawing the heat treated carbon from said reactor.    -   d. Removing sulfur contaminants from a gas stream by passing        said gas stream, to which a small percentage of air or oxygen        (0.01% to 5%) has been added, through the heat treated carbon to        allow absorption and reaction of the sulfur species with the        absorbent carbon.    -   e. Removal of the absorbent carbon for use as a horticultural,        agricultural product or for use as a sulfur impregnated        activated carbon.    -   f. Using the heat treated carbon directly after step c as a        horticultural, agricultural product or for use as an activated        carbon.

In an embodiment, the carbon absorption material is from anaerobicdigestate from animal manure.

In another embodiment, the temperature of the vessel (thermal reactor)is from 500° C.-900° C., and more preferably at or around 850° C.

In another embodiment, the gas is humidified nitrogen, carbon dioxide,exhaust gas from a combustion process, anaerobic digestion gas.

In another embodiment, the thermal treatment time is preferably between30 minutes and 3 hours, and more preferably around 1 hour.

In another embodiment, the process is a two step process: a dry gasthermal treatment at 500° C. or greater, followed by a humidified gastreatment at or around 850° C.

In another embodiment, the exit gas from the reactor is used as asupplemental fuel for providing heat for the thermal reactor.

In another aspect, there is provided a method for producing a carbonabsorbent material from anaerobic digestate, comprising: feedingdewatered anaerobic digestate into a thermal reactor which is heated toa temperature of at least 500° C.; passing humidified gas through theanaerobic digestate in the thermal reactor for a period of at least 30minutes; and withdrawing heat treated absorbent carbon after coolingfrom the thermal reactor.

In an embodiment, the anaerobic digestate comprises one or more ofanimal manures and agricultural wastes.

In another embodiment, the anaerobic digestate comprises animal manuresprocessed into heat treated absorbent carbon which remains structurallyintact despite losing hydroxyl groups of its cellulose and hemicellulosecontent.

In another embodiment, the temperature of the thermal reactor rangesfrom 500° C. to 900° C.

In another embodiment the temperature of the thermal reactor is at oraround 850° C.

In another embodiment, the humidified gas is one or more of nitrogen,carbon dioxide, exhaust gas from a combustion process, and anaerobicdigestion gas.

In another embodiment, the method further comprises humidifying the gasto a relative humidity in a range between 2% and 95%.

In another embodiment, the relative humidity of the gas is greater than10%.

In another embodiment, passing the humidified gas through the anaerobicdigestate in the thermal reactor ranges for a period of 30 minutes to 3hours.

In another embodiment, the humidified gas through the anaerobicdigestate in the thermal reactor proceeds for between 45 and 75 minutes.

In another embodiment, passing the humidified gas through the anaerobicdigestate in the thermal reactor proceeds for about 60 minutes.

In another aspect, the method comprises providing a dry gas thermaltreatment at 500° C.; and providing a humidified gas treatment between800° C. and 900° C.

In another embodiment, the humidified gas treatment is completed ataround 850° C.

In another embodiment, the method further comprises using the exit gasfrom the reactor as a supplemental fuel for generating heat for thethermal reactor.

In another embodiment, the method further comprises using the absorbentcarbon produced, to remove gaseous contaminants such as hydrogen sulfideor organic sulfur containing species from anaerobic digestion gas,landfill gas by adding air or oxygen at a concentration of 0.01% to 5%to gas to be cleaned and passing the mixture through a bed of absorbentcarbon.

In another embodiment, the method further comprises using the heattreated absorbent carbon which has been used for removing hydrogensulfide or organic sulfur containing species from anaerobic digestiongas, landfill gas as a horticultural, agricultural product or as asulfur impregnated activated carbon.

In another embodiment, the method further comprises using the heattreated absorbent carbon directly as a horticultural, agriculturalproduct for retaining moisture and nutrients in soils.

Although this disclosure has described and illustrated certain preferredembodiments of the invention, it should be pointed out that theinvention is not restricted to those particular embodiments. Theembodiments of the invention in which an exclusive property or privilegeis claimed are defined in the claims.

1. A method of producing a carbon absorbent material, the methodcomprising: providing a quantity of carbon source; heating the quantityof carbon source to at least 400° C., after said heating, activating thecarbon source thereby producing activated carbon by directing theactivation gas into contact with the quantity of carbon source; andusing exhaust gas to fuel heating of carbon source, the exhaust gasbeing the flow of activation gas after contacting the quantity of carbonsource and including volatile hydrocarbons captured from the quantity ofcarbon source.
 2. The method of claim 1, wherein: the carbon sourcecomprises biomass.
 3. The method of claim 1, wherein: the carbon sourcecomprises anaerobic digestate.
 4. The method of claim 1, furthercomprising: before said activating, humidifying the flow of activationgas to a relative humidity of between 2% and 95%.
 5. The method of claim1, further comprising: before said activating, humidifying the flow ofactivation gas to a relative humidity of at least 10%.
 6. The method ofclaim 1, wherein: using the exhaust gas to fuel heating of carbon sourcecomprises using the exhaust gas to fuel the heating of the quantity ofcarbon source.
 7. The method of claim 1, wherein: using the exhaust gasto fuel heating of carbon source comprises using the exhaust gas to fuelheating of another quantity of carbon source.
 8. The method of claim 1,further comprising: removing substantially all moisture, and hydroxylgroups from hemicellulose and cellulose from the quantity of carbonsource by the heating.
 9. The method of claim 1, wherein: the carbonsource comprises one or more of animal manure, agricultural waste, andfood waste.
 10. The method of claim 1, wherein: the activation gas isone of nitrogen gas, and carbon dioxide gas.
 11. The method of claim 1,further comprising: forming a porous open structure in the carbonsource.
 12. The method of claim 11, wherein: forming the porous openstructure comprises forming a carbonized hollow tubular structure in thecarbon source.